How well does a linear static finite element analysis predict measured strains from a nuclear package tie-down system during rail transportation?

Freight rail is often the preferred method for transportation of dangerous goods. One particular application is the use of rail to convey radioactive material in purpose-built packages. During transit, packages are secured to a rail wagon bed with a tie-down system. The design of tie-down systems varies considerably depending on the package type and rail vehicle; for example, shackles, turnbuckles, tie rods, gravity wells or transport frames are all commonly used. There are also a large number of different packages in existence that all vary in size and mass, typically 1–7 m in length and 100 kg–100 t in mass. Despite the uniqueness of many transport configurations, the design of tie-down systems is always carried out using a limited set of design load cases as defined in the appropriate Codes of Practice and Standards. Many authors have suggested that the load cases within the standards need revision or question which load cases should apply to which scenario. In a previous experiment, accelerations and strains have been measured on a freight wagon and transport frame of a heavy package during a routine rail journey. From these data, a new insight into the magnitude and nature of loading has been gained. In the present study, the measured accelerations have been used as input to a finite element model of the transport frame, and a method based on correlation between predicted and measured strains has been developed to determine an appropriate low-pass filter cut-off frequency, f_c, which separates quasi-static loading from raw dynamic data. The residual dynamic measurements have been assessed using signal processing techniques to understand their significance. The finite element model has also been used to assess the presence of contact and boundary nonlinearities and how they affect the agreement between measured and predicted strains.